The Volvo 240 model vehicles come with front and rear brake pads. The brake pads are enclosed inside of a brake caliper that is mounted to each brake rotor. When the driver pushes in on the brake pedal, the brake caliper pushes the brake pads toward the inside and outside facings of the brake rotor. As the brake pads are dragging against the turning brake rotor, the friction from the brake pads causes the brake rotor to stop turning. Inspect the pads for replacement between 35,000 and 45,000 miles.
Instructions
- 1
Drive the Volvo 240 to a safe working location with a flat surface. Apply the parking brake to prevent the Volvo from rolling.
2Loosen the lug nuts from each front wheel with a lug nut tool, such as a tire tool or a lug wrench. Do not remove any of the lug nuts.
3Slide the floor jack under the Volvo 240 and position the jack under a safe jacking point. Jack the 240 up high enough for the safety stands to fit under the car. Place the safety stands under the side rails near the front wheels. This will allow the safety stands to safely and securely hold the weight of the front end. Lower the jack until the 240 is resting on top of the stands. Always leave the floor jack under the vehicle in the up position as an additional safety precaution.
4Finish removing each lug nut from each front wheel. Pull each front wheel off the wheel hubs and place the wheels on their side to prevent them from rolling away.
5Go to the driver side wheel hub assembly and locate the access hole in the middle of the brake caliper. Pry the outboard brake pad against the cylinder inside of the caliper using the small pry bar. Pry the outboard brake pad until it pushes the cylinder in enough to be able to pull the caliper off of the rotor.
6Locate the two slide pin bolts on the back of the brake caliper. Loosen and remove the bottom slide pin bolt with a ratchet and a metric socket. Loosen only the top slide pin bolt with the ratchet and socket.
7Pivot the bottom of the brake caliper upward until the brake caliper is up as far as it will go. Wrap a bungee strap around the caliper and hook the other end of the bungee strap to the frame rail or to a nearby steering component. This will hold the brake caliper up out of the way so that the brake pads can be replaced.
8Pull the inboard brake pad out of the retaining clip with your hand. Position the C-clamp into the brake caliper and compress the outboard brake pad toward the caliper cylinder until the cylinder is flush with the outside of the cylinder entrance. Unscrew the C-clamp and remove it from the caliper. Pull the outboard brake pad from the retaining clip.
9Position the new pads into both retaining clips inside of the caliper. Remove the bungee strap and pivot the caliper back over the brake caliper. Screw the bottom slide pin bolt back into the caliper. Tighten both slide pin bolts with the ratchet and metric socket. Slide the wheel back on the hub and secure the wheel with the lug nuts. Tighten each lug nut until the wheel turns.
10Repeat the same steps above to replace the brake pads for the remaining three wheels. Jack the Volvo 240 up and remove the safety stands. Lower the 240 to the ground and pull the jack out.
11Finish tightening each lug nut with the lug nut tool until all are completely tightened.
12Get in the driver's seat and crank the engine. Pump the brake pedal to the floor and back up again two to three times to fit the brake pads to the brake rotors. Then, test drive the Volvo 240 in a safe area to check out the operation of the new brake pads.
